System and method for plug milling / flow-back / live descaling integrated improved workflow operations

ABSTRACT

A system for plug milling/flowback/descaling operations utilizes a data management component to receive and analyze data. A fluid management physical interconnection component has a debris separation device, a pressure control device and at least one mechanism connected for gas management and flow measurements of solids and liquids. The analysis by the data management component is used to provide control signals for use in or for the pressure control device. A vacuum/flush solid management system utilizes a combination of flush and vacuum pumps to convey solids in a slurry to a low pressure tank for disposal. The system directs frac sands through the debris separation device, through the pressure control device, and through the at least one mechanism for gas management and flow measurements to the low pressure tank.

BACKGROUND

The present invention relates generally to valve and equipmentassemblies and, more particularly, to an improved system and method forPlug Milling/Flow-back integrated improved workflow operations.Additionally, the same system and method can be used for live descalingoperations, since the presence the solids and hydrocarbons can bemanaged safely with the same.

The prior art plug milling/flowback systems are manually operated.Automatic and/or coordinated operation of the system components such asautomatic control of choke size and/or pump rates is not available. Theprior art for plug milling/flow-back operations requires considerablehuman intervention such as manual extraction of plug material, which ismore hazardous. The prior art utilizes high pressure separation of thefrac sand early in the process that requires heavy equipment. The samelimitations are applicable to live descaling operations. These and otherdisadvantages of the prior art are discussed in more detail hereinafterin conjunction with the drawings.

SUMMARY OF THE INVENTION

An object of the present invention is an improved plug milling flowbacksystem which can also be applied for live descaling well operations.

An advantage of the present invention is the option to automaticallycontrol functions of the system such as automatic selection of chokesizes and/or pump rate of the coiled tubing unit whereby the componentsof the system work advantageously together rather than being workedwithout regard to each other.

Another advantage of the present invention is avoidance of the need formanual removal of the plug debris or larger solids from descaling toenhance safety of operation by means of flush and vacuum pumpsinterconnected between a debris separation module and a unique lowpressure liquid/solids tank where gas, solids and liquids may beseparated.

Yet another advantage of the present invention is the elimination ofhigh pressure equipment to remove frac sands/solid scales wherebyinstead frac sands and scales are connected to pass through multiplesections of the fluid management system into the low pressureliquid/solids tank.

These and many other objects and advantages will become apparent from areview of the present specification.

One general aspect includes a system for plug milling/flowback/livedescaling operations. The system includes a coiled tubing unit; a datamanagement component may include a data aggregation portion, an analysismodule and a control system; and a fluid management physicalinterconnection component may include a debris separation device, apressure control device may include a choke, and at least one mechanismconnected for gas management and for flow measurements of solids andliquids; where said data management component receives coiled tubingdata, choke measurement data, and flow measurements of said solids andsaid liquids. Other embodiments of this aspect include correspondingcomputer systems, apparatus, and computer programs recorded on one ormore computer storage devices, each configured to perform the actions ofthe methods.

Implementations may include one or more of the following features. Thesystem where said data management component is operable to providecontrol information for operation of said fluid management physicalinterconnection component. Said data management component is operable toautomate operation of said fluid management physical interconnectioncomponent based on an analysis of flow measurements of said solids andsaid liquids. A fluid management physical interconnection component mayfurther include a tank for liquid and solids, a water treatment module,and a flush and vacuum system for solids management. The fluidmanagement physical interconnection component is configured to separateplug debris or larger solid particles from frac sands or smaller solids,gas, and pumped fluid, and to utilize said flush and vacuum system toconvey said plug debris or larger solid particles to said tank forliquids and solids. The system is operable to monitor pressures,temperatures, gas flow rates, and solid and liquid flow rates, analyzethis data and use it for control purposes. Said tank for liquid andsolids may include a plurality of weir plates and a sparging system.Said pressure control device may include a plurality of valves and atleast four chokes and said data management component is operable toautomatically choose which choke size or choke branch of said at leastfour chokes to utilize for operation of said pressure control device.Said data management component and said fluid management physicalinterconnection component are substantially entirely installed ininterconnectable trailers. Said at least one mechanism connected for gasmanagement and for flow measurements of solids and liquids may include aliquid gas separator that is configured to operate near atmosphericpressure. Said control system controls a choke size for said pressurecontrol device. Choke measurement data and said flow measurements ofsaid solids and said liquids may be used for selection of a pump ratefor said coiled tubing unit. Implementations of the described techniquesmay include hardware, a method or process, or computer software on acomputer-accessible medium.

One general aspect includes a system for plug milling/flowback/livedescaling operations. The system includes a coiled tubing unit; a lowpressure tank for disposal; a data management component; and a fluidmanagement physical interconnection component that may include a debrisseparation device, a pressure control device may include at least onechoke, and at least one mechanism connected for gas management and flowmeasurements of solids and liquids, a solid management system mayinclude a combination of flush and vacuum pumps, said solid managementsystem being connected to convey solids in a slurry to said low pressuretank for disposal. Other embodiments of this aspect includecorresponding computer systems, apparatus, and computer programsrecorded on one or more computer storage devices, each configured toperform the actions of the methods.

Implementations may include one or more of the following features. Thesystem may include a water treatment system connected to said lowpressure tank to produce recycled water. Said data management componentreceives coiled tubing data, choke measurement data, and flowmeasurements of said solids and said liquids and produces controlsignals for said pressure control device. Said control signals areutilized to select a choke size for said pressure control device. Thesystem where said solid management system is configured so that operatorcontact for removal of plug debris is eliminated. Implementations of thedescribed techniques may include hardware, a method or process, orcomputer software on a computer-accessible medium.

One general aspect includes a system for plug milling/flowback/livedescaling operations. The system also includes a coiled tubing unit; adata management component; a fluid management physical interconnectioncomponent may include a debris (larger solid particles) separationdevice, a pressure control device may include at least one choke, and atleast one mechanism connected for gas management and for flowmeasurements of solids and liquids, and a tank for liquid and solids;and where said fluid management physical interconnection component isconfigured so that frac sands or smaller solids are directed to flowthrough said debris separation device, through said pressure controldevice, through said at least one mechanism connected for gas managementand flow measurements of solids and liquids, and into said tank forliquid and solids. Other embodiments of this aspect includecorresponding computer systems, apparatus, and computer programsrecorded on one or more computer storage devices, each configured toperform the actions of the methods.

Implementations may include one or more of the following features. Thesystem where said data management component is configured to receivecoiled tubing data, choke measurement data, and flow measurements ofsaid solids and liquids and produces control signals for said pressurecontrol device. The system may include a solid management system mayinclude a combination of flush and vacuum pumps, said solid managementsystem being connected to convey solids in a slurry from said debrisseparation device to said tank for liquid and solids. Implementations ofthe described techniques may include hardware, a method or process, orcomputer software on a computer-accessible medium.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description and claims are merely illustrative ofthe generic invention. Additional modes, advantages, and particulars ofthis invention will be readily suggested to those skilled in the artwithout departing from the spirit and scope of the invention. A morecomplete understanding of the invention and many of the attendantadvantages thereto will be readily appreciated by reference to thefollowing detailed description when considered in conjunction with theaccompanying drawings, wherein like reference numerals refer to likeparts and wherein:

FIG. 1A is a high-level operation description diagram prior to wellplugs being drilled out.

FIG. 1B is a high-level operation description diagram showing a locationof scaling in a well bore.

FIG. 2 is a diagram of a prior art Plug Milling/Flow-back system.

FIG. 3 is a diagram of a Plug Milling and/or Flow-back and/or Descalingsystem and method in accord with one embodiment of the presentinvention.

DETAILED DESCRIPTION

For decades, unconventional oil and gas reserves were not accessible dueto the tight oil and gas reservoir characteristics. Reservoir Fracturingwas a key element to enable the production from such reservoirs. Thereservoir fracturing process requires the installation of multiple plugsin the wellbore to provide isolation to the different zones beingfractured. Those plugs are drilled after the fracking operation isconcluded to allow the connection of the reservoir to the well bore.This allows the production of the reservoir. The Frac Plug Drill Out(FPDO) operations are normally done by Coiled Tubing (CT) equipment andFlow Back Well Test equipment (FBWT) after the fracturing equipment isdemobilized from the site. The operations of CT and FBWT are essentialto ensure the wellbore and the reservoir connect and allow thehydrocarbons to be produced. Following the milling of plugs, a flowperiod is normally conducted, where further frac fluids, solids andhydrocarbons are recovered to the surface temporary facilities. Thisinitial recovery of frac fluids is essential to guarantee that the fullextent of fractures are connected to the well bore and will latercontribute to the production. Also, the reservoir drawdown andoverbalance are important variables in this process, as they can lead tofracture closure or non-connection, leading to future production losses.Control of parameters, process stabilization and reservoir understandingcombined can improve the final production of the wells.

Another situation that occurs on the hydrocarbon well lifecycle is theaccumulation of scales, which are product of downhole chemical reactionsand eventually lead to the choking of the production tubing, limitingthe outcome of hydrocarbons of this well. Those scales are in form ofhard solids that are removed mechanically, chemically or combined bothmethods for removal. It requires coil tubing equipment to allow theproper chemicals placement and mechanical removal. Planning for thisoperation is supported by well surveys using different access methodssuch as wireline or slick line or even coil tubing special tools. Thereis a special interest for live descaling since the avoidance ofreservoir infiltration with “killing fluids” will allow fasterproduction recovery and avoidance of additional costs to eventuallytreat for formation damage or long flowbacks for fluid recovery. Livedescaling operations have additional execution challenges, when comparedwith overbalance descaling, especially when toxic gases like H2S andNaturally occurring radioactive material (NORM) maybe present. In thosescenarios, a wide and random solid distribution, potentiallyradioactive, in presence of toxic gases, flammable hydrocarbons, highpressure streams, need to be managed safely, with minimum direct humanintervention or contact with the return medias.

Looking at FIG. 1A, a basic description of the well operation setup 10can be seen. Coiled tubing units are well known. The coiled tubing unit12 comprises coiled tubing that runs through the Christmas Tree and thePressure control equipment (PCE), 14 that provides the safety barriersfor pressure integrity. The bottom hole assembly (BHA) 16 contains amilling tool to allow for the frac isolation plugs 18 to be removed fromthe wellbore. Removal of the plugs provides connection of reservoir 20and fractures 22 to the wellbore 24. While milling, the pressurestabilization is a complex task. The residual fracture pressure, thenatural reservoir pressure and the accommodation of the frac sands inthe fractures 20 create an operational challenge to stabilize pressure,flowrate, solid returns (removed from the well bore). Lack of controlcan easily lead to shocks in the reservoir formation and risks offracture closure and expelling of solids to the well bore. The flow thatcirculates out of the BHA 16 depending on the pressures, viscosity andrate will carry the plug milling debris, proppant frac, residual gas andliquid hydrocarbon. Those returns are carried to the surface in theannulus between the wellbore 24 and the CT pipe, which is conductedthrough surface piping 26 to the Flowback well test equipment 28. Whenit comes to descaling a similar coil tubing equipment is deployed, butthe downhole scenario changes. Other than milling plugs and cleaning theresidual proppant frac, now the coil tubing will apply variousmechanical and chemical techniques that will lead to the removal of thescales 17, shown in FIG. 1B, that are mostly in solid form back to thesurface The composition of prior art systems varies but can be describedin general terms by the FIG. 2 .

Looking to FIG. 2 , a diagram of a generalized prior art FPDO, FBWT andlive descaling system 200 is shown. The coiled tubing has a pump rate202 and depth 204, which comprise the CT (coiled tubing) data 206. A CTunit oversees a series of parameters. A few parameters have a biggerimpact on the final fracture connection and protection than others, thesame applies for live descaling. The fluid input 210 is produced bycontrolling the pump rate 202 and pressure feedback 236. Themilling/jetting operations are controlled with the drill motor and mill16, depth of CT 204, weight on string, and other factors by a first teamof operators. On the fluid returns side, a second team of operators, theFlowback team, controls the choke size at the pressure control device226 to stabilize the overall system pressure to the required pressureand receive the returns. The returns are composed of residual reservoirgas 218 (occasional for FPDO and constant for live descaling), residualreservoir liquid hydrocarbon (occasional for FPDO and constant for livedescaling), pumped-in fluid 210 returns (predominant media for FPDO),plug debris/bigger solids 214 and fracturing sands/finer solids 216 thatremained or were expelled in the well bore and near well bore areas, orgenerated by the scale disaggregation. Generally, large pieces of plugdebris/bigger solids are removed from the stream 222 followed by sandremoval/finer solids 224, a pressure control element (via a choke valveor expendable choke system, (ECS) 226 and fluids have either aseparation stage or go to waste pits or tanks 228.

Due to the high pressure, flowrates, the abrasive and potentiallysour/radioactive environment, and due to possible presence of toxicgases and NORM, the tools available for flow rate measurements are verylimited, being not widely used due to accuracy and poor results.Furthermore, the sand and solids produced and associated to highpressure also often cause “wash-out” or erosion of pipes and equipment,which leads to loss of process control and integrity of the system.Several accidents are recorded in the Oil and Gas industry related tothose scenarios. Often plug debris/bigger solids are manually removed234 where a strainer vessel has to be isolated, depressurized andaccessed to allow an operator to collect the pieces into a container.This operation has a high operator exposure as often only a singlebarrier is present and also the small instrumentation liners used fordepressurization are exposed to extremely abrasive fluids, leading tocomplete wash-outs. On the sand/finer solids separation 224, thepractice is to remove the solids “as upstream as possible” to reduce theexposure of other regular FBWT/live descaling equipment. This solidseparation concept leads to high pressure separation systems, which areheavy, expensive and limited in adapting to the operating windows.Different methods are used, between sand traps, filters and cyclonic orcombination of the above. Flush equipment 230 is used with thesand/solid separator isolated (off-line) or in-stream (live), usingexternal fluids to push the accumulated solids out to a solid box 232.In some cases, the pressure from the system is used to push theaccumulated solids out as option. Handling high concentration of solidswith high pressure creates a high risk of erosion for valves,instrumentation lines and pipe.

The CT and FBWT/live descaling systems are normally operated with a lowdegree of integration as shown in FIG. 2 , with data distributed only inthe CT and FBWT modules. Decisions are motivated by execution time, riskof getting CT stuck, and pipe or equipment erosion as the main concerns,as they can lead to loss of pressure containment and exposure ofpersonnel in the surroundings. Currently the activity is clustered, andno data/action interlink happens between the blocks. This limits theactions to the clusters themselves, where operators may individuallytake decisions that are not favorable to efficiency, such as, if the CTdo a single “bite” to bring more solids in one trip. This may be moreefficient usage of the coiled tubing, which makes less runs, but maylead to excess sand at surface causing multiple problems that can leadto downtime. Additional problems with the prior art include, but are notlimited to: Erosion and the inherent integrity related issues, Lack offlow measurements and leading to potential lack of process control,Limited or inexistent sampling due to valve erosion risks, Pluggingissues leading to process upsets and downtime, Limited Process meteringand process instrumentation due to harsh conditions, Distributed data indifferent locations and work units, Solids handling with people exposureto the effluents and pressure, Generalized lack of process knowledge dueto limited data acquisition, caused by the challenges of addinginstruments in harsh environment, and Multiple heavy assets and complexrig-up.

Turning now to FIG. 3 , a diagram shows the present system and methodfor integrated plug milling and flow-back operations (live descaling).The present invention provides an innovative workflow for FPDO and FBWT,which allows better process controls leading to process safety, pressureintegrity, operational efficiency and production improvements. Thesystem is composed of two main components, a data management component350 and a fluid management physical interconnection component 360. Thesystem architecture and the individual features are applied to achievesolid separation and measurements of liquid and solids for all coiledtubing related well intervention operations. This system architecture,through safely managing the effluent and the harsh operatingenvironment, allows for a higher degree of instrumentation, leading tovaluable process insights that were not possible in the prior art. Theproposed solids management and its strategy of safely moving the solidsto downstream, with minimized erosion and plugging risks allows forapplication of standard instruments in points of the process where itwasn't possible in the prior art. Any process optimization is highlydependent on the degree of available information and what you choose todo with it. Following this logic, the present system aims to benefit bya new level of access to samples and measurements to allow betterdecisions, both human or machine based, that will lead to operationalefficiency and process safety.

The data needs to flow to allow information to be converted intoactionable insights with specific objectives. The main listed objectivesare to allow the proper assessment of the traditional concerns, asdescribed hereinbefore in reference to FIG. 2 , and to integrate all theprocess parameters in a single unit to allow more efficient dataprocessing. The data processing includes, but is not limited to, properselection of pump rates, circulation rates, choke sizes to regulatesystem pressure, protection of fractures downhole via data analysis (notthe direct intention of this invention, although it will provide thesupport to achieve it), data storage to allow future learning by workersor artificial intelligence and provide a base output for fullyautonomous system. The process works as a simple interactive cycle,where process changes lead to new input parameters seeking for liveoptimizations for the new current conditions. Coiled tubing data 306obtains the pump rate 302 and the depth 304 of the coiled tubing millingassembly. The pump rate 302, which is normally given by the coiledtubing data system 306 as a measurement from a positive displacementpump (piston type normally) needs to be synchronized with the Pressurecontrol device 326, which may have a complete automatic control option,so that the user can set a pressure target and the device compensatesfor the process variations, or the device is set fixed and the processwill vary accordingly. The choke measurement data and feedback 342 iscomposed of multiple variables, such as pressures, temperatures, openingand other control parameters, which allows for a better, human ormachine, selection of pump rate 302.

The commands, or control information, for the choke are given by theFlowback control system 330. This system allows for multiple operationmode layers, from manual to fully automatic with the required overridesto allow for back-up manual operations in case of extreme processdegradation or equipment failure. The system also removes the need ofthe operators to be in direct contact with the equipment. In thesimplest operations mode (manual), the system utilizes remote electriccommands, which eliminate the need of direct contact or proximity by theoperator with the equipment. The data flow from CT system 306, fromChoke measurements 342, from Flow measurements 332 into Welltest/flowback centralized data aggregation portion or platform 308 to befurther processed in the Flowback data analysis module 328 to providethe actionable insight to the Flowback control system 330. The Flowbackdata analysis 328 is based on the interpretation and answering of thefollowing questions: How much pressure? How much temperature? AreHydrocarbons present? How much solids production? How much Gasproduction? How much liquid production? What is the choke opening? Whattype of liquids? All of those questions can also be placed in thetransient domain by asking: how has this parameter changed? The systemtrends can be analyzed, and the combinations of those main processanswers will provide the human or machine, the capabilities to takebetter decisions and differentiate the potential events or underbalanceconditions, fluid losses, fracture unfavorable flow conditions, excesssolids production, and the like.

The Fluid management component 360 is the physical interconnection ofthe different equipment blocks and how each participates in the process.In one embodiment of the present invention, these equipment componentsmay include, but are not limited to: A debris separator 322 in thehigh-pressure section, to allow the collection of the bigger pieces ofsolids from milling of plugs and minimized operator exposure. Pressurecontrol device 326 provides pressure reduction (stabilization and/orautomation) of the stream that includes all the fine solids. Effluentseparation (gas/liquid/solid) split is provided in gas management/flowmeasurement 334. Liquid solid separation occurs in tank 336. Solid massbalance trough measurements and the calibration methods 346 aredeveloped to improve accuracy. Pumped in fluid filtration and treatmentallow fluid re-use from water treatment system 338 as recycled water.Solid handling trough vacuum/flush system 340 provides multiplealternatives of flushing points and solids collection.

The fluid management physical interconnection component 360 isconfigured to separate plug debris from frac sands, gas, and pumpedfluid, and to utilize the flush and vacuum system 340 to convey plugdebris to the tank 336 for liquids and solids.

Another difference is that unlike the prior art, the frac sands/finersolids are not separated at high pressure. Instead, as shown in FIG. 3 ,frac sands/finer solids are directed to flow through the debrisseparation device 322, through said pressure control device 326, throughthe at least one mechanism connected for gas management and flowmeasurements of solids and liquids 324 and into the tank 336 for liquidand solids.

Safe access to sampling points as the system manages the effluent streamsafely to low pressure. With a simplified and innovative workflow, wherecritical data like liquid and solid flowrate are available, incombination with automation of pressure control tasks, the solidhandling capabilities of the system without precedents, new limits canbe achieved. The proposed system architecture has a much safer conceptof solids handling, which also allows for more solids handlingcapability and overall efficiency. The debris separation step 322 isintended to filter the bigger solid particles that can create issues tothe next device in the stream. This equipment is composed of potssimilar to the Plug & trash catchers, with millimeter scalestrainer/filter (typical 5 mm holes strainer), with the difference ofbeing vertical, with higher volume and allowing to be emptied withoutthe need to be opened. Also, the filter device can be of differentshapes, being short and allowing solids collection on the whole potbody, or being long, with the collection happening in the filter ID. Thecollection can only be achieved by the application of Vacuum and flush340 from different access points in the solid retainer vessel. The flushpump can push solids from the vessel directly, trough access points inthe sides and top, or using the fitted venturi in the bottom of the pot,which allow the flush line to create some negative pressure todisaggregate the solids and carry them. As a last resource, the vacuumcan be used in batches to move the solids out. All the solids areaccumulated in the vacuum vessel and pumped as slurry to disposal pitsor a tank. Or if flushed, the solids can be directly sent for disposal.

The pressure control device 326, normally called the Choke manifold, isa combination of hydraulic and manually operated gate valves,instrumentation flanges, and choke valves, both fixed type andadjustable type. This manifold has to operate in the presence the highconcentration of solids and high-pressure flow, which is an extremelyabrasive condition. The stream nature (liquid dominant, no compressiblefluid or gas present, compressible fluid) will lead to different erosionmechanisms, and both have to be treated with different operationalstrategies and a common mechanical arrangement that addresses both isneeded. The first feature is the use of two choke valves to reduce thepressure in steps. The first, being a “drilling” choke valve, with aquick opening profile, using a plug/seat type of mechanicalconstruction, fitted with an actuator and feedback, that will allowremote and automatic operations, and eventually degraded operations withthe override system. To compensate for the exit jet effects(incompressible stream) and velocity increase due to expansion(compressible stream), a spacer joint with bigger diameter or an angulararrangement may be used to allow for a blast blind flange on a blockthat can be easily replaced. Both configurations can be used dependingon the specific flow parameters for the system being deployed. Differentunits may use one or the other system according to the more specificflowrate and space requirements. Downstream this joint or blockarrangement there will be the second choke valve. This choke valve isfitted with the fixed orifice type. The pressure breakdown strategy intwo steps enhances the life of the choke valves and surroundingequipment considerably in both operating stream types. The combinationof fixed beam plus automatic adjustable choke allows for pressurestabilization independently of the process variations. The 1^(st) valvewill automatically modulate to a certain position to compensate forvariations and achieve a given pressure set point, which is normallydesired in FPDO operations. Alternatively, the valves can be set to aposition and the process variations will lead to pressures and flowratevariations, which may normally be desired in FBWT, when the well isflowing.

The arrangement will allow for reduced velocities in the equipment andtherefore enhance the life in high concentration of solids. The Gasmanagement/flow measurement 334 plus the calibration of measurement 346can happen in the same module, if desired. The presence of gas isn'tdesired in the FPDO operations, as it is predominantly an overbalanceoperation. But, in some occasions gas comes while drilling the plug, orpotentially a more serious loss of over balance. In order to helpidentifying quickly that presence of Hydrocarbon gas, a meter anddetection system is installed in the gas line outlet of the device, toallow the operation team to spot and act quickly in that event and alsorecord the event for further investigations and procedures improvement.In the case of live descaling the hydrocarbons will be always presentand that won't present a risk or a problem, since the equipment canhandle it. Given the need to reduce restrictions in that line and thedetection criteria, an ultrasonic full-bore type of meter is applied. Ina preferred embodiment, the vessel used for this purpose has a set ofinlet devices to improve the gas separation from stream, as the gasmigrating to liquid can create other problems on the downstream liquidoutlet, such as measurement errors, higher velocity and degassing in thedownstream tank. The meter used for this application is a mass meterfitted with diagnosis tools based on multi-frequency technology, beingthis diagnosis is essential to indicate the meter is operating withinthe right conditions to validate the measurements of the liquid andsolids mass. The meter provides a mass output, that can be furtherprocessed to extract the split between liquid and solids. Thismeasurement will then be validated by a large quantitative sampleextracted from the process in the calibration system 346. The flow isdeviated for a short time to a separated enclosed tank, which issupported by load cells. The initial load values can be offset from themeasurements. The tank is filled, with the stream content, aftersettling an overall mass is recorded, the tank has a filtered suctionline and a set of internals that reduce the movement of solids to thatpoint, after draining, solids will be “as dry as possible” and measuredits mass. These values can all be compared to the periods before andafter the “calibration run” and correction factor can be introduced. Thecalibration tank also has a gas vent and can be flushed or vacuumed toensure it is clean for the next run. In summary, gas efficiencyseparation is enhanced, gas is metered and presence of hydrocarbonindicated, liquid and solids leg will not contain gas, and if they dothe meter can get indication of that, which is used as a measurementquality control, mass is measured, post processing allows for the masssplit of solids and liquid and a correction factor based on thecalibration factor found is applied to adjust the measurement accuracy.

Accordingly, a system for improved workflow in plugmilling/flowback/descaling operations is provided that may comprise adata management component further comprising a centralized dataaggregation platform, an analysis module and a control system.

Additionally a fluid management physical interconnection componentfurther comprises a debris separation device, a pressure control device,a gas management and flow measurements device, a tank for liquid/solids,a water treatment module and a flush/vacuum system for solidsmanagement.

The data management component analyzes a plurality of fluid and solidcharacteristics of a return fluid to automate operation of said fluidmanagement physical interconnection based on a predefined set ofvariables for said fluid and solid characteristics.

The fluid management component separates the plug debris/bigger solidsin the high-pressure section and safely conveys all the remaining solidsto the downstream part of the process.

In one embodiment, the system is operable to monitor remotely from humancontact attributes such as pressures, temperatures, gas flow rate, solidand liquid mass flow rate and trough calculations. The system may deductthe split of the mass, with the support of calibration procedure thatuses actual flow conditions data and samples, measuring the solids andliquid content. An alternative method allows the application of aliquid/solid split correction coefficient.

A solid management system is provided that is based on combined flushand vacuum pumps. The flush can be direct or with venturi to createsuction effect on bottom of vessels. Vacuum can be provided with adedicated tank and with batch operation. This system is connected instrategic process locations to allow sparging, dynamic vacuum and flushwith the intention to convey solids in the slurry to low pressure tanksfor disposal, eliminating the operator contact with it. Thus, the systemreduces people's exposure.

A rugged solid resistant design of pressure control device is provided,with automatic\manual pressure or position control, with at least twoactuated gate valves with double barrier, making a total of eightisolation valves, four chokes, fixed and actuated, split in two flowbranches with spacer flow joint or angular block with cushion blindflanges to enhance the resistance to operate in the presence of solids.

A modular system is designed to reduce mobilization and demobilizationmechanical lifting and complexity, having equipment substantiallyentirely installed in interconnectable trailers and having themechanical arrangements to allow for the minimum use of externalequipment. The modules also allow for the adaptation of extra tanks andflow equipment according to the specific operations requirements.

A unique liquid/solid tank design allows handling of liquids and solidsin large quantities, containing multiple engineered weir plates,sparging/circulation systems and with some capacity to handle gas, thistank provides enhanced oil/water separation prior to the next fluidprocessing step.

A high efficiency liquid gas separator is designed to work as close aspossible to atmospheric pressure improves separation. The separator hasa gas meter installed that has no obstructions, and a customized carryunder preventer valve to enhance process safety.

A debris separation device with accumulation vessels is designed toseparate the bigger debris pieces from the main stream using troughgravity and filtration, with engineered flush and vacuum ports to allowthe solids removal without operator contact

A modular trailer mounted system is provided with optimized connectionsand for improved mobilization time.

The water treatment system considers and allows the connection ofdifferent water treatment methods.

A pressure control device allows for setting a fixed pressure target sothat the choke valve can be automatically modulated to compensate forthe process variations and achieve the desired pressure set point.

A method is provided to reliably extract liquid and solid mass splitfrom a mass meter and applies correction factors and quality control tovalidate the measurement.

The use of a full-bore metering device may be used in the separator gasline to ensure the detection of hydrocarbon and the quantification ofit.

A meter site calibration method with dedicated equipment is based on alarge volume sample, and mass measurements and drainage system.

The foregoing description of the preferred embodiments of the inventionhas been presented for purposes of illustration and description only. Itis not intended to be exhaustive or to limit the invention to theprecise form disclosed; and many modifications and variations arepossible in light of the above teaching. Such modifications andvariations that may be apparent to a person skilled in the art areintended to be included within the scope of this invention as defined bythe accompanying claims.

1. A system for well operations, comprising: a coiled tubing unit; adata management component comprising a data aggregation portion, ananalysis module and a control system; and a fluid management physicalinterconnection component comprising a debris separation device, apressure control device comprising a choke, and at least one mechanismconnected for gas management and for flow measurements of solids andliquids; whereby said data management component receives coiled tubingdata, choke measurement data, and flow measurements of said solids andsaid liquids.
 2. The system of claim 1 wherein said system is configuredto operate for at least one of coil plug milling, flowback, ordescaling.
 3. The system of claim 2, wherein said data managementcomponent is operable to provide control information for operation ofsaid fluid management physical interconnection component.
 4. The systemof claim 3, wherein said data management component is operable toautomate operation of said fluid management physical interconnectioncomponent based at least in part on an analysis of said flowmeasurements of said solids and said liquids.
 5. The system of claim 3wherein said a fluid management physical interconnection componentfurther comprises a tank for liquid and solids, a water treatmentmodule, and a flush and vacuum system for solids management.
 6. Thesystem of claim 5 whereby said fluid management physical interconnectioncomponent is configured to separate plug debris from frac sands, gas,and pumped fluid, and to utilize said flush and vacuum system to conveysaid plug debris to said tank for liquids and solids.
 7. The system ofclaim 6, said system is operable to monitor pressures, temperatures, gasflow rate, and solid and liquid flow rates.
 8. The system of claim 2wherein said pressure control device comprises a plurality of valves andat least four chokes and said data management component is operable toautomatically choose which of said at least four chokes to utilize foroperation of said pressure control device.
 9. The system of claim 2,wherein said data management component and said fluid managementphysical interconnection component are substantially entirely installedin interconnectable trailers.
 10. The system of claim 5, wherein saidtank for liquid and solids comprises a plurality of weir plates and asparging system.
 11. The system of claim 2 wherein said at least onemechanism connected for gas management and for flow measurements ofsolids and liquids comprises a liquid gas separator that is configuredto operate near atmospheric pressure.
 12. The system of claim 2 whereinsaid control system controls a choke size for said pressure controldevice.
 13. The system of claim 2, wherein choke measurement data andsaid flow measurements of said solids and said liquids are used forselection of a pump rate.
 14. A system for well operations, comprising:a coiled tubing unit; a low pressure tank for disposal; a datamanagement component; and a fluid management physical interconnectioncomponent comprising a debris separation device, a pressure controldevice comprising at least one choke, and at least one mechanismconnected for gas management and flow measurements of solids andliquids, a solid management system comprising a combination of flush andvacuum pumps, said solid management system being connected to conveysolids in a slurry to said low pressure tank for disposal.
 15. Thesystem of claim 14 wherein said system is configured to operate for atleast one of coil plug milling, flowback, or descaling.
 16. The systemof claim 15, further comprising a water treatment system connected tosaid low pressure tank to produce recycled water.
 17. The system ofclaim 15, wherein said data management component receives coiled tubingdata, choke measurement data, and flow measurements of said solids andsaid liquids and produces control signals for said pressure controldevice.
 18. The system of claim 17, wherein said control signals areutilized to select a choke size for said pressure control device. 19.The system of claim 17 whereby said solids comprise plug debris, saidsolid management system is configured so that operator physical contactwith said plug debris for removal of said plug debris is eliminated. 20.A system for well operations, comprising: a coiled tubing unit; a datamanagement component; a fluid management physical interconnectioncomponent comprising a debris separation device, a pressure controldevice comprising at least one choke, and at least one mechanismconnected for gas management and for flow measurements of solids andliquids, and a tank for liquid and solids; and wherein said fluidmanagement physical interconnection component is configured so that fracsands are directed to flow through said debris separation device,through said pressure control device, through said at least onemechanism connected for gas management and flow measurements of solidsand liquids, and into said tank for liquid and solids.
 21. The system ofclaim 20 wherein said system is configured to operate for at least oneof coil plug milling, flowback, or descaling.
 22. The system of claim21, wherein said data management component is configured to receivecoiled tubing data, choke measurement data, and flow measurements ofsaid solids and liquids and produces control signals for said pressurecontrol device.
 23. The system of claim 21, further comprising a solidmanagement system comprising a combination of flush and vacuum pumps,said solid management system being connected to convey solids in aslurry from said debris separation device to said tank for liquid andsolids.